Hypertherm Powermax 65 Service Manual

TroubleshooTing and sysTem TesTs
powermax 65/85 Service Manual 5-35
Problem Meaning Causes Solution
Arc goes out while
cuttingor intermittently
willnot fire.
The arc lost contact
with the workpiece.
• The work lead
or work lead
connection may
be faulty.
• The material
being cut may
require the use of
continuous pilot
arc mode.
• If you are cutting expanded metal, grate,
or any metal with holes, set the mode
switch to continuous pilot arc mode.
• Check for loose connections at the work
clamp and at the power supply.
• Reposition the work lead on the
workpiece.
• Clean the cutting surface to ensure a
better connection with the work lead.
Faulty fan.
• The fan could be
overloading the
flyback circuit.
• Perform Tests 5 and 11.
The cut quality is poor
orthe cut does not sever
the metal.
The consumables
are worn, there is
a poor work lead
connection, the
output from the
power supply is
too low, the power
board is producing
low current, or the
selected cutting
mode is incorrect..
• The consumables
need to be
replaced
• Inspect the consumables and replace if
necessary.
• The work lead
may be damaged
or not properly
connected to the
work piece
• Inspect the work lead for damage.
Reposition it and clean the work surface
to ensure good contact.
• The amperage
adjustment knob
may be set too
low.
• Increase the amperage as needed.
• The power board
(PCB3) may be
faulty.
• Perform Tests 1, 2, and 3 and replace
any faulty components.
The cutting mode
switch is in the
wrong position
for the cutting
operation.
• Ensure the cutting mode switch is in the
correct position.
• Faulty pilot arc
IGBT.
• Turn the power OFF, remove the
consumables, and check the resistance
between the cathode and the work
clamp. If the resistance is less than
5kΩ, check the resistance across the
pilot arc IGBT (two screws on 08). If the
resistance is less than 5kΩ, replace the
pilot arc IGBT.

Hypertherm Powermax 65 Specifications

General

Open Circuit Voltage (OCV)	300 VDC
Gas Supply	Clean, dry, oil-free air or nitrogen
Maximum Cut Capacity (Mild Steel)	1" (25 mm)
Input Voltage	200-600 V, 1/3-PH, 50/60 Hz
Output Current	20 – 65 A
Duty Cycle	50% @ 65 A
Recommended Gas Inlet Flow Rate/Pressure	6.7 scfm @ 85 psi
Torch Lead Length	25 ft (7.6 m)
Maximum Cut Capacity (Aluminum)	5/8" (16 mm)
Severance Cut Capacity (Mild Steel)	1-1/4" (32 mm)
Maximum Severance Thickness	1-1/4 in (32 mm)
Gas Type	Air/Nitrogen
Torch Options	Hand Torch, Mechanized Torch